Dual-Wire Drive Roll Layout for Wider Weld Beads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding technologies face challenges in increasing the width or length of the weld bead without simultaneously increasing the heat input and energy consumption, as larger electrodes are often required to achieve desired weld profiles, which may not be ideal for mechanical applications.
Innovation Solution
A dual wire configuration using two welding wires of different diameters, where one is larger and the other is smaller, are fed through a system with drive rolls having circumferential grooves to maintain contact and control the deposition, allowing for a wider or longer weld puddle without the need for increased energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a larger electrode diameter is used to increase weld bead width or length, then the weld puddle width and length are improved, but the energy consumption and heat input increase
Solution Approach 1:
The patent applies segmentation by using multiple smaller electrodes (e.g., two or more wires) instead of a single large electrode. Each electrode contributes to the overall weld bead formation, allowing the welder to achieve the desired weld bead width and length through the combined effect of multiple smaller electrodes, thereby reducing the energy consumption associated with using a single large electrode while maintaining the required weld geometry
2Duration of action of moving object
If a larger electrode diameter is used to increase weld puddle length, then the molten metal duration is improved, but the heat input increases
Solution Approach 1:
The patent uses multiple smaller electrodes to extend the weld puddle duration. By having multiple electrodes feeding molten metal simultaneously, the weld puddle is maintained for a longer period as each electrode contributes to the molten pool, achieving the desired duration without requiring a single large electrode that would increase heat input and energy consumption
3Productivity
If a larger electrode diameter is used to increase wire deposition rate, then the deposition speed is improved, but the energy consumption increases
Solution Approach 1:
The patent merges the function of multiple smaller electrodes to achieve a high wire deposition rate. By simultaneously feeding multiple electrodes through the welding system, the total deposition rate equals the sum of individual electrode deposition rates, matching or exceeding the rate of a single large electrode while consuming less energy since each smaller electrode requires less energy to operate
4Area of stationary object
If a larger electrode diameter is used to cover wider weld gap, then the gap coverage is improved, but the weld bead profile becomes non-ideal
Solution Approach 1:
The patent segments the welding task across multiple smaller electrodes, each contributing to covering different portions of the weld gap. This allows the welder to achieve wide gap coverage through the combined width of multiple electrodes while maintaining ideal weld bead profiles, as each smaller electrode creates a more controlled and aesthetically pleasing bead shape compared to a single large electrode
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for a controlled weld bead width or length enhancement without excessive energy consumption, enabling more efficient welding operations and the creation of desired weld profiles for various mechanical applications by combining different consumables to achieve desired weld chemistry.
Implementation Method 1
drive rolls having circumferential grooves to maintain contact and control the deposition
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A welding or additive manufacturing wire drive system includes a welding wire spool (101, 103) and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire (E1), drawn from the welding wire spool (101), and located between the drive rolls in the circumferential groove, and a second welding wire (E2), drawn from the welding wire spool (103), and located between the drive rolls in the circumferential groove. The first welding wire (E1) contacts the second welding wire (E2) between the first drive roll and the second drive roll. The first welding wire (E1) further contacts a first sidewall portion of the circumferential groove, and the second welding wire (E2) further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire (E1, E2) are radially offset from a central portion of the circumferential groove.